Option 1
Roll-end front tuck mailer
Opens from the front like a drawer. Works with a tear strip for a clean first open.
Box type
Custom Corrugated Mailer Boxes
A mailer box is the shipping carton that doubles as the unboxing. It has to protect the product in transit, open without a knife, and still look like the brand when it lands. We match flute grade, opening style and insert to the product weight and the route it travels.
500pcs per size, minimum
100+box types produced
3–5days, digital sample
15–22working days, bulk
Specification
- Minimum order
- 500 pcs per size
- Board
- E-flute, B-flute or BC double wall, depending on weight
- Opening
- Tear strip, tuck top or front-lock roll end
- Sample
- Digital printed sample 3–5 days; production-run sample 7–10 days
- Bulk lead time
- 15–22 working days after sample approval
- Packing
- Flat-packed in export cartons, bundled per size
Typical use
- Direct-to-consumer e-commerce
- Subscription and repeat shipments
- Kits and starter sets
- Products sold through marketplaces
Not on the list? The construction does not change — the board, insert and finish do. Send the product details and we will tell you which of these options fits.
Construction options
Each option changes the dieline, the assembly time and the unit cost. We quote the two that fit your brief rather than all four.
Option 2
Tuck-top mailer
Top-opening carton with a tuck flap. Simpler construction and lower cost.
Option 3
Two-piece mailer
Separate lid and base in corrugated, for heavier products and reuse.
Option 4
Mailer with tear strip
A perforated strip opens the box without a blade, which protects both product and print.
Board and materials
- E-flute corrugated
- B-flute corrugated
- BC double-wall corrugated
- White-top kraft corrugated
- Recycled kraft corrugated
Finishing
- Flexo printing for large runs
- Digital printing for short runs
- Litho-laminated top sheet
- Matte varnish
- Interior print
Inserts
- Corrugated fitment
- Die-cut EVA foam
- Paperboard platform
- Molded pulp insert
- Honeycomb paper wrap
Material and finish are specified per project and confirmed on the sample. Where a material claim matters — recycled content, plastic-free insert — the specification states what the material is, so the claim can be checked rather than assumed.
How this box gets made
Fixed specification, then dieline, then sample, then bulk — in that order.
Spec and quote
Product, quantity, channel and date fixed. Itemised quote issued.
Dieline
Dieline PDF issued with your artwork placed and finishing marked.
Digital sample
3–5 days, to check design, colour and finish.
Production sample
7–10 days, on bulk board and process. Signed off as the reference.
Bulk
15–22 working days after approval, with inspection and packing data.
Corrugated Mailer Boxes: questions before ordering
Which flute should I use?
It depends on product weight, fragile parts and the shipping route. E-flute is typical for light retail goods, B-flute for mid-weight, and double wall for heavy or long-distance shipments. We recommend one after seeing the product and its packed weight.
Can the mailer be printed on the inside?
Yes. One-colour interior print is common for a short message or a return instruction, and it costs far less than full-colour interior coverage.
Will the box survive international courier handling?
Flute grade, corner clearance and insert design are set for the route. For multi-leg shipments we test the packed weight against the board grade before quoting.
What is the minimum order?
500 pcs per size.
Other box types
Box type
Folding Cartons
Printed folding cartons on 300–400 gsm board, flat-packed for efficient freight. 500 pcs per size, digital or offset printing.
View page →
Box type
Rigid Gift Boxes
Rigid gift boxes built on 1.5–3 mm greyboard, wrapped and finished to your artwork. 500 pcs per size, dieline and physical sample before bulk.
View page →
Box type
Magnetic Closure Boxes
Rigid magnetic closure boxes with concealed magnets, ribbon pull and foam or paper inserts. 500 pcs per size, sample in 3–5 days.
View page →
Request a quote
Quote a corrugated mailer boxe
Send five things — product, channel, quantity, budget and target date. We come back with two or three options, the trade-offs between them, and an itemised quote.
- Email · sales@colormixpackaging.com
- Based in · Guangzhou, China
- Response time · within one business day
- Minimum order · 500 pcs per size